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Mitsubishi 4G1 manual

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Table of contents for the manual

  • Page 1

    GENERAL INFORMA TION 1 1A-0-3 ........................................... 1. SPECIFICA TIONS 1 1A-1-1 ................................................. SERVICE SPECIFICA TIONS 1 1A-1-1 .................................... REWORK DIMENSIONS 1 1A-1-3 ........................................ T ORQUE SPECIFICA TIONS 1 1A-1-4 ...........................[...]

  • Page 2

    1 1A-0-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation NOTES[...]

  • Page 3

    4G1 ENGINE (E - W) - General Information 1 1A-0-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation GENERAL INFORMA TION[...]

  • Page 4

    4G1 ENGINE (E - W) - General Information 1 1A-0-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation[...]

  • Page 5

    4G1 ENGINE (E - W) - General Information 1 1A-0-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Descriptions 4G13 12-V AL VE - CARBURET OR 4G13 12-V AL VE - MPI T ype In-line OHV , SOHC In-line OHV , SOHC Number of cylinders 4 4 Combustion chamber Pentroof type Pentroof type T otal displacement dm 3 1,299 1,299 Cylinder bore mm 71.0 71.0 Pist[...]

  • Page 6

    4G1 ENGINE (E - W) - General Information 1 1A-0-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Descriptions 4G13 16-V AL VE - MPI 4G18 16-V AL VE - MPI T ype In-line OHV , SOHC In-line OHV , SOHC Number of cylinders 4 4 Combustion chamber Pentroof type Pentroof type T otal displacement dm 3 1,299 1,584 Cylinder bore mm 71.0 76.0 Piston strok[...]

  • Page 7

    4G1 ENGINE (E - W) - General Information 1 1A-0-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Descriptions 4G15 - CARBURETT OR 4G15 - MPI T ype In-line OHV , SOHC In-line OHV , DOHC Number of cylinders 4 4 Combustion chamber Semi spherical type Pentroof type T otal displacement dm 3 1,468 1,468 Cylinder bore mm 75.5 75.5 Piston stroke mm 82[...]

  • Page 8

    NOTES[...]

  • Page 9

    4G1 ENGINE (E - W) - Specifications 1 1A-1-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 1. SPECIFICA TIONS SERVICE SPECIFICA TIONS Item Standard Limit Rocker arms, rocker shafts, and camshaft Camshaft cam SOHC 12-V AL VE Intake (primary) 38.78 38.28 height mm Intake (secondary) 38.78 38.28 Exhaust 39.10 38.60 SOHC 16-V AL VE Intake 36.99 3[...]

  • Page 10

    4G1 ENGINE (E - W) - Specifications 1 1A-1-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Item Limit Standard Overall valve length SOHC 12-V AL VE Intake 100.75 100.25 mm Exhaust 101.05 105.55 SOHC 16-V AL VE Intake 1 1 1.56 1 1 1.06 Exhaust 1 14.71 1 14.21 DOHC Intake 106.35 105.85 Exhaust 106.85 106.35 V alve spring free SOHC 12-V AL VE In[...]

  • Page 11

    4G1 ENGINE (E - W) - Specifications 1 1A-1-2a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Item Standard Limit Crankshaft and cylinder block Crankshaft end play mm 0.05 - 0.18 0.25 Crankshaft journal diameter mm 48.0 - Crankshaft pin diameter mm 42.0 - Crankshaft journal oil clearance mm 0.02 - 0.04 0.1 Cylinder block gasket surface flatness[...]

  • Page 12

    4G1 ENGINE (E - W) - Specifications 1 1A-1-2b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added[...]

  • Page 13

    4G1 ENGINE (E - W) - Specifications 1 1A-1-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REWORK DIMENSIONS Item Standard Limit Cylinder head and valves Cylinder head oversize valve guide SOHC 12-V AL VE 0.05 O. S. 12.050 - 12.068 - hole diameter mm 0.25 O. S. 12.250 - 12.268 - 0.50 O. S. 12.500 - 12.518 - SOHC 16-V AL VE 0.05 O. S. 10.550 -[...]

  • Page 14

    4G1 ENGINE (E - W) - Specifications 1 1A-1-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation TORQUE SPECIFICA TIONS Item Nm Alternator and ignition system W ater pump pulley bolt 9 Alternator brace (alternator side) 22 Alternator brace (tightened with water pump) 23 Alternator pivot bolt 44 Oil level gauge guide 23 Crankshaft bolt 125 Spark plu[...]

  • Page 15

    4G1 ENGINE (E - W) - Specifications 1 1A-1-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Item Nm Thermo valve 27 W ater temperature gauge unit 11 W ater temperature sensor 29 W ater pump 13 Exhaust manifold and intake manifold Boost sensor 5 Solenoid valve assembly 9 Intake manifold 17 Intake manifold stay (MPI) M8 17 M10 21 Intake manifold[...]

  • Page 16

    4G1 ENGINE (E - W) - Specifications 1 1A-1-5a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Item Nm Crankshaft and cylinder block Flywheel 132 Drive plate 132 Rear plate 10 Bell housing cover 10 Rear oil seal case 11 Bearing cap bolt 51 Oil pressure switch 18 Knock sensor 23 PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added[...]

  • Page 17

    4G1 ENGINE (E - W) - Specifications 1 1A-1-5b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added[...]

  • Page 18

    4G1 ENGINE (E - W) - Specifications 1 1A-1-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOL TS Parts of the engine use plastic region tightening bolts. The tightening procedure for these is different from that of conventional bolts a nd is described in relevant parts of this manual. Not[...]

  • Page 19

    4G1 ENGINE (E - W) - Specifications 1 1A-1-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. T o ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and locat[...]

  • Page 20

    NOTES[...]

  • Page 21

    4G1 ENGINE (E - W) - Special T ools 1 1A-2-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 2. SPECIAL TOOLS T ool Number Name Use MB990767 End yoke holder Holding camshaft sprocket when loosening or tightening bolt (used with MD998715) MD99801 1 Crankshaft rear oil seal installer Installation of crankshaft rear oil seal MD998054 Oil pressure [...]

  • Page 22

    4G1 ENGINE (E - W) - Special T ools 1 1A-2-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation T ool Use Name Number MD998760 V alve stem seal installer Installation of valve stem seals (SOHC 12-V AL VE) MD998780 Piston pin setting tool Removal and press-fitting of piston pins MB991659 Guide-D Guide for removal and press-fitting of piston pins MD[...]

  • Page 23

    4G1 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 3. AL TERNA TOR AN D IGNITION SYSTEM REMOV AL AND INST ALLA TION <SOHC 12-V AL VE> 22 Nm 6 7 44 Nm 23 Nm 4 123 Nm 8 9 3 2 23 Nm 1 11 25 Nm 10 13 12 12 Nm 9N m 5 Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4.[...]

  • Page 24

    4G1 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-1a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE - FRONT WHEEL DRIVE> 22 Nm 6 7 44 Nm 23 Nm 4 125 Nm 8 9 3 2 23 Nm 1 11 25 Nm 10 13 12 12 Nm 9N m 5 Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt* 5. [...]

  • Page 25

    4G1 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-1b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE - REAR WHEEL DRIVE> 22 Nm 6 7 44 Nm 23 Nm 4 125 Nm 8 9 3 2 23 Nm 1 11 10 Nm 10 13 13 Nm 9N m 5 14 21 Nm 15 12 25 Nm 9N m Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-r[...]

  • Page 26

    4G1 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 22 Nm 6 7 44 Nm 23 Nm 4 103 Nm 8 9 3 2 23 Nm 1 25 Nm 10 13 12 11 N m 9N m 5 11 Removal steps 1. Oil level gauge 2. Oil level gauge guide 3. O-ring 4. Drive belt* 5. W ater pump pulley 6. Alternato[...]

  • Page 27

    4G1 ENGINE (E - W) - Alternator and Ignition System 1 1A-3-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINT A A " CRANKSHAFT BOL T REMOV AL (1) Lock t he flywheel or drive plate in position using t he special tool shown in the illustration, then loosen the crankshaft bolts. INST ALLA TION SER VICE POINTS " A A[...]

  • Page 28

    NOTES[...]

  • Page 29

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 4. TIMING BEL T REMOV AL AND INST ALLA TION <SOHC> 11 N m 1 10 12 35 Nm 4 3 7 2 5 23 Nm 88 Nm 11 9 8 9N m 13 6 Removal steps 1. T iming belt upper cover 2. T iming belt lower cover A A "" C A 3. T iming belt " B A 4. T ensioner spring[...]

  • Page 30

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 11 N m 1 7 9 10 35 Nm 4 3 6 2 5 23 Nm 88 Nm 8 35 Nm 11 13 12 11 N m 11 N m Removal steps 1. T iming belt upper cover 2. T iming belt lower cover A A "" D A 3. T iming belt A A "" B A 4. T ension[...]

  • Page 31

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINTS A A " TIMING BEL T / TENSIONER SPRING / TIMING BEL T TENSIONER REMOV AL (1) Using pliers, grip the tensioner spring projection (marked “A” in the diagram)and remove it from the oil pump case stopper . Then, remove the ten[...]

  • Page 32

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (7) Abnormal wear on teeth Initial stage: Canvas worn (fluffy canvas fibers, rubbery texture gone, white discoloration, canvas texture indistinct) Final stage: Canvas worn, exposing rubber (tooth width reduced) (8) Missing teeth 2. TENSIONER PULLEY AND ID[...]

  • Page 33

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (3) Grip the other tensioner spring projection and fit it onto the oil pump case lug as shown in th e illustration. (4) Move th e timing belt tensioner in th e direction shown and temporarily tighten the bolt. " C A TIMING BEL T INST ALLA TION (1) Al[...]

  • Page 34

    4G1 ENGINE (E - W) - T iming Belt 1 1A-4-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " D A TIMING BEL T INST ALLA TION (1) Place t he camshaft sprocket timing marks at the positions shown. NOTE After aligning t he sprocket timing marks, let go of the sprockets. The exhaust camshaft sprocket will rotate by one tooth in the direction s[...]

  • Page 35

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 5. FUEL AND EMISSION CONTROL SYSTEMS REMOV AL AND INST ALLA TION <SOHC - CARBURETOR> 17 Nm 11 N m 22 Nm 21 Nm 11 12 10 9 8 7 3 2 4 5 6 1 Removal steps 1. Breather tube 2. Fuel hose 3. Fuel pump 4. Gasket 5. Insulator 6. Gasket 7[...]

  • Page 36

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC - MPI> 11 N m 18 Nm 21 Nm 18 Nm 9N m 1 2 3 11 6 4 5 9 10 8 7 15 14 13 12 Removal steps 1. Throttle body assembly 2. Gasket 3. Fuel return pipe " B A 4. Fuel pressure regulator 5. O-ring 6. [...]

  • Page 37

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-2a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC - REAR WHEEL DRIVE> 11 N m 18 Nm 21 Nm 9N m 1 2 3 11 6 4 5 9 10 8 7 13 12 9N m Removal steps 1. Throttle body assembly 2. Gasket 3. Fuel return pipe " B A 4. Fuel pressure regulator 5. O-r[...]

  • Page 38

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-2b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added[...]

  • Page 39

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 11 N m 11 6 2 1 18 Nm 9N m 3 5 4 9 10 8 7 Removal steps 1. Throttle body assembly 2. Gasket 3. Fuel return pipe " B A 4. Fuel pressure regulator 5. O-ring 6. Insulator 7. Insulator " [...]

  • Page 40

    4G1 ENGINE (E - W) - Fuel and Emission Control Systems 1 1A-5-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation INST ALLA TION SER VICE POINTS " A A INJECT OR INST ALLA TION (1) Fit a new O-ring and grommet onto the injector . (2) Apply spindle oil or gasoline to th e injector O-ring. (3) Fit the injector onto the delivery pipe, turning it[...]

  • Page 41

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 6. W A TER PUMP AND W A TER HOSE REMOV AL AND INST ALLA TION <SOHC - CARBURETOR> 11 N m 1 2 3 4 5 6 7 8 9 10 11 12 13 14 27 Nm 27 Nm 22 Nm 23 Nm 12 Nm 13 Nm Removal steps 1. W ater hose 2. W ater hose 3. W ater hose " F A 4. The[...]

  • Page 42

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC - MPI> 2 13 Nm 12 10 9 11 12 Nm 11 N m 4 29 Nm 3 8 7 6 22 Nm 5 23 Nm 1 Removal steps 1. W ater hose 2. W ater hose " E A 3. W ater temperature sensor " D A 4. W ater temperature gauge unit [...]

  • Page 43

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-2a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE - MPI - FRONT WHEEL DRIVE> 2 13 Nm 12 10 9 11 12 Nm 11 N m 4 29 Nm 3 8 7 6 22 Nm 5 23 Nm 1 12 Nm Removal steps 1. W ater hose 2. W ater hose " E A 3. W ater temperature sensor "[...]

  • Page 44

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-2b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE - MPI - REAR WHEEL DRIVE> 2 13 Nm 12 11 10 12 Nm 11 N m 4 1 25 Nm 9 8 23 Nm 23 Nm 5 7 6 29 Nm 3 12 Nm Removal steps 1. W ater hose 2. W ater hose " E A 3. W ater temperature sensor &[...]

  • Page 45

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 2 13 Nm 12 10 9 11 12 Nm 11 N m 4 29 Nm 3 8 7 6 22 Nm 5 23 Nm 1 12 Nm Removal steps 1. W ater hose 2. W ater hose " E A 3. W ater temperature sensor " D A 4. W ater temperature gauge unit [...]

  • Page 46

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation INST ALLA TION SER VICE POINTS " A A W A TER PUMP INST ALLA TION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the mounting surface. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent. " B A O-RING / [...]

  • Page 47

    4G1 ENGINE (E - W) - W ater Pump an d W ater Hose 1 1A-6-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " F A THERMO V AL VE INST ALLA TION (1) If the thermo valve is to be reused, apply the specified sealant to its thread. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent.[...]

  • Page 48

    NOTES[...]

  • Page 49

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 7. INT AKE A ND EXHAUST MANIFOLDS REMOV AL AND INST ALLA TION <SOHC - CARBURETOR> 17 Nm 1 2 3 4 5 6 7 8 30 Nm 17 Nm 29 Nm Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket 5. Exhaust [...]

  • Page 50

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC - MPI> 1 3 4 44 Nm 5 9 8 7 29 Nm 6 17 Nm 2 21 Nm 17 Nm 17 Nm Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket 5. Oxygen sensor (vehicles for Hong Ko[...]

  • Page 51

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-2a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE - MPI - REAR WHEEL DRIVE> 2 4 5 17 Nm 11 10 9 29 Nm 8 3 21 Nm 17 Nm 17 Nm 29 Nm 6 7 1 5N m 9N m 19 Nm Removal steps 1. Boost sensor 2. Engine hanger 3. Intake manifold stay 4. Intake mani[...]

  • Page 52

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-2b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC - CARBURETOR FOR CENTRAL AMERICA> 2 4 5 17 Nm 11 10 9 54 Nm 8 30 Nm 17 Nm 11 N m 29 Nm 6 7 1 13 Nm 83 Nm 8 3 12 Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake ma[...]

  • Page 53

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 1 3 4 9 8 7 29 Nm 6 17 Nm 2 21 Nm 17 Nm 17 Nm 5 44 Nm 29 Nm Removal steps 1. Engine hanger 2. Intake manifold stay 3. Intake manifold 4. Intake manifold gasket 5. Oxygen sensor 6. Exhaust manifold c[...]

  • Page 54

    4G1 ENGINE (E - W) - Intake and Exhaust Manifolds 1 1A-7-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation INST ALLA TION SER VICE POINTS " A A REED V AL VE, BRACKET AND AIR PIPE INST ALLA TION (1) Insert the lower en d of the air pipe into the exhaust manifold, then tighten the pipe nut temporarily . (2) Fit the upper end of the air pipe [...]

  • Page 55

    NOTES[...]

  • Page 56

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 8. ROCKER ARMS AND CAMSHAFTS REMOV AL AND INST ALLA TION <SOHC 12-V AL VE> 15 Nm 1 5 2 3 6 4N m 9 14 13 7 12 11 15 16 17 21 20 19 22 10 8 31 Nm 18 4 Apply engine oil to all moving parts before installation. Removal steps 1. Breather ho[...]

  • Page 57

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-1a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE> 35 Nm 9N m 31 Nm 1 2 3 4 5 6 10 11 12 13 14 15 16 17 18 19 20 21 9N m Apply engine oil to all moving parts before installation. 9 8 7 Removal steps 1. Breather hose 2. P .C.V . hose 3. Oil[...]

  • Page 58

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-1b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added[...]

  • Page 59

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> 24 Nm 1 2 3 5 4 6 7 9 11 12 13 14 15 11 N m 10 8 Apply engine oil to all moving parts before installation. 4N m Removal steps 1. Breather hose 2. P .C.V . hose 3. P .C.V . valve 4. P .C.V . valve gask[...]

  • Page 60

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation INSPECTION 1. CAMSHAFT (1) Measure the cam heights and replace the camshaft if any height exceeds the specified limit. Standard value mm Limit mm Intake SOHC 12-V AL VE 38.78 38.28 SOHC 16-V AL VE 36.99 36.49 DOHC 34.67 34.17 Exhaust SOHC 12[...]

  • Page 61

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (3) While gently pushing down the internal steel ball using special tool MD998442, move the plunger through 5 to 10 strokes until it slides smoothly . In addition to eliminating stiffness in the plunger , this operation will remove dirty oil[...]

  • Page 62

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (7) Place the lash adjuster in container C. Then, gently push down the internal steel ball using special tool MD998442. Caution Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pres[...]

  • Page 63

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation NOTE Replace the lash adjuster if the time measurement is out of specification. (13)Place the lash adjuster in container C again, then gently push down the internal steel ball using special tool MD998442. (14)Stand the lash adjuster with its[...]

  • Page 64

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " B A BEARING CAP INST ALLA TION (1) Position the camshaft dowel pins as shown. NOTE With the camshaft dowel pins in this position, t he camshaft notches for tightening cylinder head bolt are correctly positioned. (2) Bearing caps Nos. [...]

  • Page 65

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-8 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " E A ROCKER ARM / ROCKER SHAFT ASSEMBL Y INST ALLA TION (1) Assemble the rocker arms and rocker shaft, paying attention to the identification marks. Then mount the assembly on the cylinder head. " F A CAMSHAFT OIL SEAL INST ALLA T[...]

  • Page 66

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-9 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " H A ROCKER COVER INST ALLA TION (1) Apply the specified sealant to the area shown, then fit the rocker cover . Specified sealant: 3M A TD part No. 8660 or equivalent V AL VE CLEARANCE ADJUSTMENT <SOHC 12-V AL VE> (1) Position th[...]

  • Page 67

    4G1 ENGINE (E - W) - Rocker Arms an d Camshafts 1 1A-8-10 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation <SOHC 16-V AL VE> (1) Position the No. 1 cylinder at top dead center on the compression stroke. (2) Adjust the valve clearance at the points shown in t he illustration. (3) Loosen the adjusting screw locknut. (4) Using a feeler gauge,[...]

  • Page 68

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 9. CYLINDER HEAD AND V AL VES REMOV AL AND INST ALLA TION <SOHC 12-V AL VE> Apply engine oil to all moving parts before installation. 1 2 22 4 5 6 14 13 17 19 7 20 8 12 21 18 16 15 11 10 9 3 Removal steps A A "" D A 1. Cylinde[...]

  • Page 69

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-1a PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <SOHC 16-V AL VE> Apply engine oil to all moving parts before installation. 1 2 4 5 6 14 13 17 19 7 8 12 18 16 15 11 10 9 3 20 Removal steps A A "" D A 1. Cylinder head bolt 2. Cylinder head assemb[...]

  • Page 70

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-1b PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Intentionally blank PWEE9520-A E Dec. 1998 Mitsubishi Motors Corporation Added[...]

  • Page 71

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL AND INST ALLA TION <DOHC> Apply engine oil to all moving parts before installation. 1 2 4 5 6 14 13 17 19 7 8 12 18 16 15 11 10 9 3 20 Removal steps A A "" D A 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylind[...]

  • Page 72

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINTS A A " CYLINDER HEAD BOL T REMOV AL A B " RET AINER LOCK REMOV AL (1) T ag removed valves, springs, and other components, noting their cylinder numbers an d locations to facilitate reassembly . Store these co[...]

  • Page 73

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation A C " V AL VE STEM SEAL REMOV AL INSPECTION 1. CYLINDER HEAD (1) Before cleaning the cylinder head, check it for water leaks, gas leaks, cracks, and other damage. (2) Remove all oil, water scale, sealant, a nd carbon. After cleaning the [...]

  • Page 74

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (3) Measure the valve’s total length. If the measurement is less than specified, replace the valve. Standard mm Limit mm Intake SOHC 12-V AL VE 100.75 100.25 SOHC 16-V AL VE 1 1 1.56 1 1 1.06 DOHC 106.35 105.85 Exhaust SOHC 12-V AL VE 101.0[...]

  • Page 75

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 4. V AL VE GUIDES (1) Measure the clearance between the valve guide and valve stem. If the clearance exceeds the specified limit, replace either or both components. Standard mm Limit mm Intake SOHC 12-V AL VE 0.020 - 0.050 0.10 SOHC 16-V AL V[...]

  • Page 76

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation V AL VE SEA T CORRECTION SERVICE POINTS (1) Before correcting the valve seat, check the clearance between the valve guide a nd valve. If necessary , replace the valve guide. (2) Using the appropriate special tool or seat grinder , correct the[...]

  • Page 77

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-8 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation V AL VE GUIDE REPLACEMENT SER VICE POINTS (1) Using a press, push the valve guide out toward the cylinder block side. (2) Rebore the valve guide hole in the cylinder head to match the oversize valve guide that is to be fitted. Caution Do not [...]

  • Page 78

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-9 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " B A V AL VE SPRING INST ALLA TION (1) Install the valve spring such that its painted end is on the rocker arm side. " C A RET AINER LOCK INST ALLA TION " D A CYLINDER HEAD BOL T INST ALLA TION (1) Before reusing the cylinder [...]

  • Page 79

    4G1 ENGINE (E - W) - Cylinder Head and V alves 1 1A-9-10 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (4) T ighten the bolts in the sequence shown until each is torqued to 49 Nm. (5) Completely loosen t he bolts. (6) Retighten the bolts in the sequence shown until each is torqued to 20 Nm. (7) Apply paint marks to the cylinder head bolt head[...]

  • Page 80

    4G1 ENGINE (E - W) - Oil Pump an d Oil Pan 1 1A-10-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 10. OIL PUMP AN D OIL P AN REMOV AL AND INST ALLA TION 11 1 12 14 13 16 15 10 9 8 6 5 7 2 3 10 Nm 13 Nm 44 Nm 18 Nm 7N m 4 39 Nm 23 Nm Apply engine oil to all moving parts before installation. Removal steps " E A 1. Oil filter 2. Drain plug[...]

  • Page 81

    4G1 ENGINE (E - W) - Oil Pump an d Oil Pan 1 1A-10-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINTS A A " OIL P AN REMOV AL (1) Remove t he oil pa n mounting bolts. (2) Knock the special tool between the oil pan and cylinder block as shown in th e illustration. (3) T apping the side of the special tool, slide the [...]

  • Page 82

    4G1 ENGINE (E - W) - Oil Pump an d Oil Pan 1 1A-10-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation INST ALLA TION SER VICE POINTS " A A FRONT OIL SEAL CASE INST ALLA TION (1) Clean the sealant application surfaces on the cylinder block and front oil seal case. (2) Apply a 3 mm bead of form-in-place gasket to the entire circumference of t[...]

  • Page 83

    4G1 ENGINE (E - W) - Oil Pump an d Oil Pan 1 1A-10-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " E A OIL FIL TER INST ALLA TION (1) Clean th e filter mounting surface on the front case. (2) Apply engine oil to the oil filter ’ s O-ring. (3) Screw on the oil filter until the O-ring is seated on the mounting surface. Then, give the o[...]

  • Page 84

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 1 1. PIST ONS AND CONNECTING RODS REMOV AL AND INST ALLA TION 6 7 8 10 12 4 9 11 5 1 2 3 Apply engine oil to all moving parts before installation. Removal steps " G A 1. Connecting rod nu t A A "" F A 2. Connecting ro d cap[...]

  • Page 85

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINTS A A " CONNECTING ROD CAP REMOV AL (1) Mark the cylinder number on th e side of th e connecting rod big end to facilitate reassembly . A B " PISTON PIN REMOV AL (1) Insert the Push Rod (special tool) from[...]

  • Page 86

    4G1 ENGINE (E - W) - Pistons and Connecting Rods (A - C) - (B - D) L= 2 1 1A-1 1-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 2. CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Wipe all oil off the crankshaft pin an d connecting rod bearing. (2) On the pin, place a plastic gauge that is cut to the same length as the bearing’ s wi[...]

  • Page 87

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (8) Mount the piston and connecting rod on the Piston Pin Setting Base (special tool) with the piston’s front mark pointing upward. (9) Install the piston pin using a press. If the press-fitting load is out of specification, replace the[...]

  • Page 88

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " C A PISTON RING No. 2 / PISTON RING No. 1 INST ALLA TION (1) Using piston ring expander , fit No. 2 and No. 1 piston ring into position. NOTE 1. The ring en d is provided with identification mark. Item Identifica- tion mark No. 1 r[...]

  • Page 89

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " E A CONNECTING ROD BEARING INST ALLA TION Identification mark positions No. 4 No. 1 No. 3 No. 2 B A 4G13, 4G15 4G18 Color code positions No. 4 No. 1 No. 3 No. 2 No. 4 No. 1 No. 3 No. 2 No. 2 No. 1 A B No. 3 No. 4 P P (1) Select bea[...]

  • Page 90

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " F A CONNECTING ROD CAP INST ALLA TION (1) Aligning the marks made during disassembly , fit t he bearing cap onto the connecting rod. If the connecting rod is new and has no index mark, ensure that the bearing locking notches are bo[...]

  • Page 91

    4G1 ENGINE (E - W) - Pistons and Connecting Rods 1 1A-1 1-8 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Caution 1. If the nuts are turned by less than 90 _ , the cap may not be held on with sufficient strength. 2. If the nuts are turned by more than 100 _ , loosen them completely and carry out the tightening procedure again. PWEE9520-A E De[...]

  • Page 92

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-1 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation 12. CRANKSHAFT AND CYLINDER BLOCK REMOV AL AND INST ALLA TION Apply engine oil to all moving parts before installation. 18 Nm 11 11 N m 10 Nm 132 Nm 16 12 51 Nm 132 Nm 10 Nm 14 22 24 1 2 3 4 5 6 7 8 9 10 17 18 19 20 21 132 Nm 13 15 22 Nm[...]

  • Page 93

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-2 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Removal steps 1. Flywheel bolt 2. Flywheel 3. Flywheel bolt 4. Adapter plate 5. Flywheel 6. Adapter plate 7. Crankshaft bushing 8. Drive plate bolt 9. Adapter plate 10. Drive plate 1 1. Crankshaft bushing 12. Rear plate 13. Bell housing [...]

  • Page 94

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-3 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation REMOV AL SER VICE POINTS A A " OIL PRESSURE SWITCH REMOV AL (1) Disconnect the oil pressure switch terminals. (2) Using the special tool, remove the oil pressure switch. Caution The thread is coated with sealant. T ake care not to b[...]

  • Page 95

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-4 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation (4) Using a cylinder gauge, measure each cylinder ’ s bore and cylindricity . If any cylinder is severely worn, bore all the cylinders to oversize and replace the piston and piston rings accordingly . T ake measurements at th e points [...]

  • Page 96

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-5 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " B A CRANKSHAFT BEARING INST ALLA TION 4G13, 4G15 Color code positions (type 1) No. 5 No. 2 Color code positions (type 2) No. 4 No. 3 No. 5 No. 2 No. 1 Identification mark positions No. 4 No. 3 No. 5 No. 2 No. 1 4G18 No. 4 No. 3 No[...]

  • Page 97

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-6 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation Crankshaft journal Cylinder block bearing diameter Bearing Range Color code Identification mark Journal diameter mm Identification mark Identification mark 1 Y ellow 1 47.995 - 48.000 0 1 1 2 2 3 2 None 2 47.985 - 49.995 0 2 1 3 2 4 3 Wh[...]

  • Page 98

    4G1 ENGINE (E - W) - Crankshaft and Cylinder Block 1 1A-12-7 PWEE9520 E Nov . 1995 Mitsubishi Motors Corporation " C A BEARING CAP INST ALLA TION (1) On the bottom surface of each bearing cap is the cap’s number and an arrow . Starting at t he timing belt side, fit the bearing caps in numerical order . Ensure that the arrows point toward th [...]

  • Page 99

    NOTES[...]